100,000 m3/Year AAC Blocks Plant to Zambia |

100,000 m³/Year AAC Blocks Plant to Zambia

In February 2025, we delivered and commissioned a 100,000 m³/Year AAC Block Plant to Zambia—aligning with its National Development Plan (2022–2026) for affordable housing and infrastructure.

Country	Zambia
Annual Capacity	100,000 m³ (Medium AAC Plant)
Plant Type	Fully-Automatic Medium AAC Block Plant
Client Type	Zambian distributor expanding beyond Lusaka
Service Provided	Full turnkey (Design + Equipment + Installation + Training + 2-Year Support + ZDA Compliance)
Delivery Time	55 days (factory → Dar es Salaam Port → 7-day inland to Lusaka)

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Why the Client Chose 100,000 m³/Year Capacity?

Our client (a Lusaka concrete block supplier) picked this medium plant to solve core concerns:

Regional Demand Match: Zambia’s total AAC demand is 180,000–220,000 m³/year, with 60% in Copperbelt/Southern/Lusaka. 100,000 m³ lets them dominate 50% of regional demand, plus supply Malawi.
Cost Efficiency: ~1.5M USD fits their budget. The plant needs 14 workers/shift (vs. 20+ for large lines) and uses sugarcane bagasse for fuel—cutting labor/energy costs by 30%.
Scalability: Easy upgrade to 180,000 m³/year in 15 months (add 1 autoclave) to meet 15% annual demand growth (2028 projection).

Detailed Equipment Configuration for AAC Blocks Plant to Zambia

All machinery is customized to Zambia’s conditions (local materials, power outages, ZDA standards) and meets SANS 12600:2011:

Equipment	Zambia-Specific Customization	Core Function
Ball Mill	High-wear liners for abrasive Zambezi sand/bagasse ash	Grinds raw materials into fine powder for uniform slurry
Automatic Batching System	Calibrated for bagasse ash (replaces 20% cement) to keep strength ≥3.5 MPa	Precisely measures materials (cement:lime:sand = 1:2.2:1.8) for consistent quality
Slurry Mixing Tank	Triple agitators (prevents sand sedimentation) + water recycling (cuts use by 30%)	Mixes powder/water into homogeneous slurry
Mold & Casting Machine	Weather-resistant stainless steel (for rainy season) + quick-release latches	Forms “green cakes” during pre-curing (4–5 hours at 48–52°C)
Air-Turning Cutting Machine	Dual blades (faster cutting) + manual backup (power outages) + dust collector	Cuts green cakes into standard/custom sizes (mining camps)
Autoclaves (2 units)	Biomass-fueled (bagasse—40% cheaper than diesel) + heat recovery (saves 28% fuel)	Strengthens blocks with high-temp steam (190–195°C for 8 hours)
Steam Boiler	Water treatment (Lusaka’s hard water) + works with bagasse/wood chips	Generates steam for autoclaves (25% more efficient than diesel boilers)
Robotic Palletizing System	Semi-automatic (cost-efficient) + weatherproof canopy (outdoor storage)	Palletizes blocks into 20-unit bundles (Zambian transport standard)

Export Process of AAC Blocks Plant to Zambia

We solved Zambia’s landlocked challenges and ZDA compliance to meet launch deadlines:

Pre-Production Prep: Tested 6 local material batches (bagasse ash, fly ash) to optimize formulas; added 30kW backup generator (for 3–4 weekly outages) and rainwater harvesting (ZDA mandate); helped secure “Pioneer Status” (10-year tax exemption).
Manufacturing Checks: 42-day production with 4 weekly client video inspections; dry runs/load tests confirmed no defects.
Shipping Docs: 12×40HQ containers via Dar es Salaam Port; all docs (COO, ZDA approval, SANS report) prepared for customs.

On-Site Installation & Operator Training

Our 5-person team spent 35 days in Lusaka:

Mechanical Setup (20 days): Adjusted for 230V/50Hz power; reinforced autoclave foundations (Lusaka’s clay soil).
Electrical Work (10 days): PLC system with English interface + backup generator integration.
Training (5 days): 14 local workers (2 female supervisors) trained on safe operation, troubleshooting, and quality checks (SANS 12600 standards).

Post-Commissioning Results

One month after launch, the AAC block line exceeded the client’s expectations, meeting all performance targets:

Autoclave of aac block manufactuing plant

Daily output: 280–310 m³ (on track for 100,000 m³/year—supplies 2,000 homes/month).
Quality: 97.5% qualification rate (strength 3.8 MPa, density 590 kg/m³).
Savings: 32% less fuel, 28% less water (~45,000 USD/year).
Contracts: Lusaka West Housing (50,000 m³), Copperbelt mining camp (30,000 m³), plus 5 Malawi/Zimbabwe inquiries.

What Our Client Says?

“We needed a plant for regional supply and ZDA compliance—this team delivered,” said Mr. Banda (Operations Director). “They tested our bagasse ash, trained locals, and got us Pioneer Status. We’re top in Copperbelt and will upgrade to 180,000 m³/year—only with them.”

Why Choose Us?

Local Expertise: We know Zambia’s materials (bagasse ash, Zambezi sand), logistics, and regulations (ZDA, Pioneer Status).
Turnkey Reliability: No hidden costs; 24/7 WhatsApp support for urgent orders.
Proven Track Record: 12+ plants in Southern Africa; 96% of clients get ROI in 2–2.3 years.
Sustainability: Help leverage waste (bagasse) for cost savings and government incentives.

Start Your AAC Block Manufacturing Plant?

Whether you are planning a small, medium, or large-scale AAC factory, we can provide complete solutions based on your land, budget, and market demand.

Contact us now to get a free feasibility study & detailed quotation. Our engineers will design the most suitable AAC plants for your needs.